Methods and apparatus for accessing hvac coil

ABSTRACT

Methods and apparatus for accessing HVAC coils according to various aspects of the present technology comprise a plenum access panel that is configured to be coupled to a plenum either upstream or downstream from an HVAC component. The plenum access panel may comprise one or more moveable sections configured to provide access into the interior of the plenum or associated ductwork without requiring the disassembly of the ductwork from the HVAC component.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 61/836,314, Jun. 18, 2013, and incorporates the disclosure of the application by reference.

BACKGROUND

Residential and commercial heating ventilation and air conditioning (HVAC) systems often include a ductwork system to direct the mass flow of treated air passing through the HVAC system to a desired location and direct untreated air to one or more components such as an air handling unit. Often, components are designed to work together to improve efficiency of the overall system. For example, components such as a furnace and an air handling unit are often coupled together so that an airflow exhausted by one component may be received by the other and subsequently heated or cooled. This airflow is then directed through the ductwork to one or more locations where the treated airflow is desired. To improve efficiency, the ductwork is commonly sealed and/or made airtight to prevent the treated airflow from leaking out of the ductwork. Although sealing the ductwork helps improve efficiency, the performance of routine maintenance on individual HVAC components may be negatively impacted since the ductwork may have to be disassembled thereby creating a possibility that the ductwork may be assembled incorrectly. This may increase costs associated with maintenance or may result in system leaks if the ductwork is reassembled incorrectly.

For example, components such as heat pumps have coils that require regular cleaning. Although these coils are positioned along an exterior of the heat pump and generally easily accessible on an uninstalled heat pump once the heat pump is installed and coupled to a plenum, the coils are contained within the sealed ductwork and are no longer accessible without disconnecting the plenum from the heat pump.

BRIEF SUMMARY

Methods and apparatus for accessing HVAC coils according to various aspects of the present technology comprise a plenum access panel that is configured to be coupled to a plenum either upstream or downstream from an HVAC component The plenum access panel may comprise one or more moveable sections configured to provide access into the interior of the plenum or associated ductwork without requiring disassembly of the ductwork from the HVAC component.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present technology may be derived by referring to the detailed description when considered in connection with the following illustrative figures. In the following figures, like reference numbers refer to similar elements and steps throughout the figures.

FIG. 1 representatively illustrates a plenum access panel coupled to a plenum in accordance with an exemplary embodiment of the present technology;

FIG. 2A representatively illustrates a close up view of the plenum and an open section of the plenum in accordance with an exemplary embodiment of the present technology;

FIG. 2B representatively illustrates a close up view of the plenum access panel positioned on the plenum in accordance with an exemplary embodiment of the present technology;

FIG. 3 representatively illustrates a front and side view of the plenum access panel in accordance with an embodiment of the present technology;

FIG. 4 representatively illustrates a rear view of the plenum access panel in accordance with an exemplary embodiment of the present technology;

FIG. 5 representatively illustrates a front and side view of a movable panel in accordance with an exemplary embodiment of the present technology; and

FIG. 6 representatively illustrates a rear views of the movable panel in accordance with an exemplary embodiment of the present technology.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The present technology may be described in terms of functional block components and various processing steps. Such functional blocks may be realized by any number of components configured to perform the specified functions and achieve the various results. For example, the present technology may employ various types of materials, sealants, fasteners, and the like, which may carry out a variety of functions. In addition, the present technology may be practiced in conjunction with any number of systems such as commercial and/or residential heating and cooling systems and the system described is merely one exemplary application for the technology. Further, the present technology may employ any number of conventional techniques for coupling ductwork, sealing ductwork, facilitating air flow, and heating and/or cooling air.

Methods and apparatus for accessing HVAC coils according to various aspects of the present technology may operate in conjunction with any suitable ventilation system and/or forced air heating and cooling system. Various representative implementations of the present technology may be applied to any duct transition and/or air return system.

Referring now to FIGS. 1, 2A, and 2B, in an exemplary embodiment of the present technology, a plenum access panel 102 may comprise a selectively accessible opening in a section of duct, such as a plenum 104 disposed upstream or downstream of a forced air system unit 106. The forced air system unit 106 may comprise an opening having a component such as a coil 204 that is positioned in the airflow path of an intake or exhaust of the forced air system unit 106. Access to the coil 204 may be prevented or otherwise hindered by the position of the plenum 104 relative to the opening when the forced air system unit 106 and the plenum 104 are coupled together. The plenum access panel 102 may be suitably configured to provide access to the coil 204 without the need to disconnect the plenum 104 from the forced air system unit 106.

The plenum 104 may comprise one or more wall elements coupled together to form an air flow passage. For example, the plenum 104 may be formed from one or more pieces of sheet metal coupled together and bent or otherwise formed into a desired shape. In one embodiment, the plenum 104 may comprise a section of interior ductwork commonly used in residential or commercial heating and/or cooling systems.

The plenum access panel 102 may comprise an access frame 206 that is configured to receive and/or attach to a panel 208. The plenum access panel 102 may be suitably configured to provide access to the interior of the plenum 104 and/or provide access to a section of the forced air system unit 106 that is covered by the plenum 104. For example, the plenum access panel 102 may be positioned along an open section 202 of the plenum 104 proximate to an intake or exhaust section 108 of the forced air system unit 106 such that when the panel 208 is moved from a closed position to an open position the coil 204 of the breed air system unit 106 may be accessible for maintenance.

The access frame 206 may be coupled to the open section 202 of the plenum 104 by any suitable method. For example, referring now to FIGS. 2-4, in one embodiment, the access frame 206 may comprise an inner opening 306 that substantially aligns with the open section 202 of the plenum 104 when the access frame 206 is coupled to the plenum 104. The access frame 206 may further comprise a plurality of tabs 302 depending outwardly from a plurality of sidewalls 304 arranged around the inner opening 306.

The tabs 302 may be configured to help secure the access frame 206 in place and may comprise any suitable device or system. For example, the tabs 302 may be suitably configured to extend into the plenum 104 and be folded or otherwise positioned against one or more edge portions 210 of the plenum 104 to secure the access frame 206 to the plenum 104.

The sidewalls 304 are configured to be placed against an exterior surface of the plenum 104 to help seal the interior of the plenum 104 from the exterior environment when the forced air system unit 106 is in use. For example, a sealant may be applied to an interior surface 310 of the sidewalls 304 that will be positioned against the duct. The sidewalls 304 may be configured to receive the panel 208. For example, the sidewalls 304 may comprise an open hem 308 along three sides of the access frame 206 that face the inner opening 306. The open hem 308 may be suitably configured to allow the panel 204 to be slideably inserted from the fourth side of the access frame 206 to selectively close off the inner opening 306.

The access frame 206 may comprise any suitable material such as sheet metal or plastic that may be exposed to heated and/or cooled air flow produced by the forced air system unit 106. The access frame 206 may also comprise and suitable size or shape. For example, in one embodiment, the access frame 206 may comprise is substantially rectangular shape of between six and thirteen inches along each side to allow sufficient access to the interior of the plenum 104.

The panel 208 provides for controllable access to the interior of the plenum 104. The panel 208 may comprise any suitable device or system to cover and/or seal the open section 202 and/or the inner opening 306 of the plenum access panel 102 such as a door, a flap, and cover, and the like. For example, in one embodiment, the panel 208 is configured to be slideably moved between a closed position and an open position to allow access through the inner opening 306 to the interior portion of the plenum 104. In a second embodiment, the panel 208 may be configured to be rotated on a hinge between a closed position and an open position to allow access through the inner opening 306 to the interior portion of the plenum 104. The panel 208 may further be configured to be securely held in the closed position by any suitable device or method such as locking tabs, pins, latches, and the like.

Referring now to FIGS. 5 and 6, in one embodiment, the panel 208 may comprise a rigid or semi-rigid structure 502 configured to slide within the open hems 308 of the sidewalk 304. The structure 502 may any suitable material configured to resist bending and/or buckling as a result of the changes in air pressure within the plenum 104 resulting from airflow through the plenum 104.

The panel 208 may further comprise a handle 504 positioned on an exterior facing surface and an insulation panel 602 disposed on an interior surface of the panel 208. In one embodiment, the handle 504 may be formed from the same material making up the panel 208. For example, the handle 504 may be formed by forming a closed hem extending outward from the exterior surface.

The insulation panel 602 may be configured to minimize heat transfer through the inner opening 306 of the plenum access panel 102. The insulation panel 602 may comprise any suitable device or system for reducing heat transfer across the panel 208. For example, in one embodiment, the insulation panel 602 may comprise a layer of insulation adhesively affixed to the interior surface of the panel 208. The insulation panel 602 may also be secured to the panel 208 by a closed hem formed from the panel 208 itself. For example, one or more panel edges 604 may be folded inward to form a receiving area for the insulation panel 602.

In operation, a plenum access panel 102 may be coupled to an open section 202 of a plenum 104. The plenum access panel 102 may be suitably configured to be positioned against the plenum 104 and at least partially extend into an interior portion of the plenum 104 through the open section 202. For example, the plenum access panel 102 may comprise a plurality of sidewalls 304 having a plurality of outwardly extending tabs 302 configured to extend into the plenum 104 when the plenum access panel 102 is positioned against the open section 202 of the plenum 104. Each of the tabs 302 may be bent towards an interior surface of the plenum 104 to thereby secure the plenum access panel 102 in place. For example, the tabs 302 may be configured to engage a plurality of edge portions 210 that define the open section 202 of the plenum 104.

The sidewalls 304 of the plenum access panel 102 may be arranged to form an inner opening 306 that is at least partially aligned with the open section 202 of the plenum 104. A panel 208 may be attached to or selectively coupled to the plenum access panel 102 to cover the inner opening 306 and seal off the interior portion of the plenum 104. The panel 208 may be selectively moved between a closed position and an open position to allow access to the interior portion of the plenum 104. For example, in one embodiment, the plenum access panel 102 may be configured to allow the panel 208 to be slid or otherwise inserted into position over the open section 202 and/or the inner opening 306 and slidably removed from the plenum access panel 102. In a second embodiment, the panel 208 may be coupled to the plenum access panel 102 and be configured to pivot between the open and closed positioned such as by a hinge.

The plenum access panel 102 may further be connected to the plenum 104 in such a way as to reduce leakage from the plenum 104 during operation. For example, a sealant such as a silicone caulk, insulated stripping material, or the like may be positioned between the sidewalls 304 and the edge portions 210. Similarly, the panel 208 may be configured to reduce a likelihood of leakage or unintended heat transfer through the inner opening 306. For example, the panel 208 may be comprise an insulated interior surface configured to reduce thermal transfer through the panel 208.

The particular implementations shown and described are illustrative of the technology and its best mode and are not intended to otherwise limit the scope of the present technology in any way. Indeed, for the sake of brevity, conventional manufacturing, connection, preparation, and other functional aspects of the system may not be described in detail. Furthermore, the connecting lines shown in the various figures are intended to represent exemplary functional relationships and/or steps between the various elements. Many alternative or additional functional relationships or physical connections may be present in a practical system.

In the foregoing specification, the technology has been described with reference to specific exemplary embodiments. Various modifications and changes may be made, however, without departing from the scope of the present invention as set forth in the claims. The specification and figures are illustrative, rather than restrictive, and modifications are intended to be included within the scope of the present technology. Accordingly, the scope of the technology should be determined by the claims and their legal equivalents rather than by merely the examples described.

For example, the steps recited in any method or process claims may be executed in any order and are not limited to the specific order presented in the claims. Additionally, the components and/or elements recited in any apparatus claims may be assembled or otherwise operationally configured in a variety of permutations and are accordingly not limited to the specific configuration recited in the claims. Benefits, other advantages and solutions to problems have been described above with regard to particular embodiments; however, any benefit, advantage, solution to problem or any element that may cause any particular benefit, advantage or solution to occur or to become more pronounced are not to be construed as critical, required or essential features or components of any or all the claims.

As used herein, the terms “comprise”, “comprises”, “comprising”, “having”, “including”, “includes” or any variation thereof, are intended to reference a non-exclusive inclusion, such that a process, method, article, composition or apparatus that comprises a list of elements does not include only those elements recited, but may also include other elements not expressly listed, or inherent to such process, method, article, composition or apparatus. Other combinations and/or modifications of the above-described structures, arrangements, applications, proportions, elements, materials or components used in the practice of the present technology, in addition to those not specifically recited, may be varied or otherwise particularly adapted to specific environments, manufacturing specifications, design parameters or other operating requirements without departing from the general principles of the same. 

1. A plenum access panel for accessing an interior portion of a plenum through an open section of the plenum defined by a plurality of edge portions, comprising: an access frame configured to be coupled to the open section of the plenum, wherein the access frame comprises: a central opening configured to substantially align with the open section of the plenum; and a plurality of sidewalls arranged around the central opening and configured to secure the access frame to the edge portions of the plenum; and a panel configured to engage the access frame and cover the central opening.
 2. A plenum access panel according to claim 1, wherein: the access frame further comprises a plurality of tabs depending outwardly from the plurality of sidewalls; and the plurality of tabs are configured to engage the edge portions of the plenum.
 3. A plenum access panel according to claim 1, wherein the access frame further comprises a plurality of open hems disposed along an exterior surface of the plurality of sidewalls, wherein the plurality of open hems are configured to slidably receive the panel.
 4. A plenum access panel according to claim 1, wherein the panel comprises: a handle depending outwardly from a first side of the panel; and an insulated surface disposed along a second side of the panel.
 5. A plenum access panel according to claim 4, wherein: the panel comprises a plurality of panel edges folded inwardly towards a center portion of the second side of the panel to form a plurality of receiving sections; and the insulated surface comprises an insulation panel configured to be inserted into the receiving sections of the panel.
 6. A method of forming an access panel for accessing an interior portion of a plenum through an open section of the plenum defined by a plurality of edge portions, comprising: coupling an access frame to the open section of the plenum, wherein the access frame comprises: a central opening configured to substantially align with the open section of the plenum; and a plurality of sidewalls arranged around the central opening and configured to secure the access frame to the edge portions of the plenum; and coupling a panel to the access frame over the central opening.
 7. A method of forming an access panel according to claim 6, wherein coupling the access frame to the open section of the plenum comprises engaging a plurality of tabs depending outwardly from the plurality of side sidewalls to the edge portions of the plenum.
 8. A method of forming an access panel according to claim 6, wherein coupling the panel to the access frame comprises sliding the panel into a plurality of open hems formed along an exterior surface of the plurality of sidewalls.
 9. A method of forming an access panel according to claim 6, further comprising: forming a handle from a first side of the panel; and forming an insulated surface along a second side of the panel.
 10. A method of forming an access panel according to claim 9, wherein forming the insulated surface along the second side of the panel comprises: forming a receiving section along the second side of the panel by inwardly folding a plurality of panel edges towards a center portion of the panel; and inserting an insulation panel into the receiving section. 